Materials Selection for Process Plants and Facilities Training
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Materials Selection for Process Plants and Facilities Training Course
Introduction:
Course Objectives:
Upon the successful completion of this course, each participant will be able to:-
· Apply proper techniques in materials selection for process plants and facilities
· Identify the materials selection criteria covering the mandatory requirements, design conditions and temperatures, process and special requirements and template information
· Describe the corrosion basics of cathodes and anodes and employ control techniques including barrier coatings, cathodic protection, anodic protection, passivation and polarization
· Define metallurgy and recognize the alloy designations, manufacturing effects, metals and alloys, non-metallic materials, coatings and linings
· Determine failure modes of the embrittlement phenomena, high-temperature effects and corrosion
· Employ corrosion testing and explain the criteria, procedures and exceptions of materials selection
· Discuss the various case studies pertaining to hydrocarbon, petrochemical and chemical processes
· Illustrate the material curves and graphs as well as employ material special applications
Who Should Attend?
This course provides an overview of all significant aspects and considerations of materials selection for those who are involved in the design, construction, operation, and maintenance of plant facilities. Experienced designers, engineers and materials engineers will benefit from the practical approach of this course. For inspection and maintenance people, the course will offer background information that can be used to recognize and evaluate corrosion in the plant and used to plan effective inspections. For the less experienced personnel, the course will offer a unique introduction to the problems that are encountered in operating plants and some of the techniques used to ameliorate the corrosion and degradation.
Course Outlines:
Materials Selection Criteria
- Mandatory Requirements
- Design Condition
- Design Temperatures
- Process Requirements
- Special Requirements
- Cost Considerations
- Life Expectancy
Corrosion
- Introduction
- Corrosion Basics (Cathodes and Anodes)
- Corrosion Control (Coatings, Linings, Cathodic Protection, Anodic Protection & Inhibitors)
Metallurgy
- Metallurgical Definitions (Heat Treatments, Microstructural Terms & Metallurgical Terms)
- Alloy Designations
- Manufacturing Processes
- Metals and Alloys (Cast Iron, Carbon Steels, Micro Alloyed Steels, Low-Alloy Steels & High Alloys and Non-Ferrous Materials)
- Non-Metallic Materials (Plastics, Elastomers, Carbon & Graphite, Glass, Cement, Refractories & Wood)
Metallurgy
- Coatings and Linings (Introduction, Thick Dielectric Barrier Coatings, Thin Dielectric Barrier Coatings, Thick Metallic Barrier Coatings, Thin Metallic Barrier Coatings, Sprayed Metal Coatings, Galvanizing & Other Coatings)
Failure Modes: Embrittlement Phenomena
- Introduction
- Carbon and Low-Alloy Steels (Temper Embrittlement, Creep Embrittlement, Strain Ageing, Hydrogen Embrittlement, Caustic Embrittlement & Low-Temperature Embrittlement)
- Stainless Steels (Ferritic Stainless Steels: 885OF (475OC) Embrittlement, Martensitic Stainless Steels, Austenitic Stainless Steels: Sigma Phase Embrittlement, Duplex Stainless Steels
- High Alloys
- Hydriding
Failure Modes: High-Temperature Effects
- Mechanical Effects (Introduction, Creep & Stress Rupture)
- Metallurgical Effects (Sensitization, Spheroidization and Graphitization of Carbon Steels & Welding)
- Chemical Effects (Carburization, Fuel Ash Corrosion, Hydrogen Gas, Nitriding, Oxidation, Suffixation & Sulfidic Corrosion)
- High-Temperature Alloys
Failure Modes: Corrosion
- Corrodents (Acids, General, Inorganic Acid, Organic Acids, Acid Salts, Amines, Ammonia, Carbon Dioxide, Caustics, Chlorides, Flue Gas, Hydrogen Sulphide, Insulation, Oxidants, Water & Seawater)
- Microbiology Influenced Corrosion (Introduction, Effect on Materials of Construction & Mitigation Methods)
- Stress Corrosion Cracking (Introduction & Crack-Inducing Agents)
- Wet Sour Service (Low-Risk Service, Simple Wet Sour Services & Severe Wet Sour Services) Corrosion Allowance (Design Life, Vessels, Heat Exchangers & Tanks & Piping)
Corrosion Testing
- Introduction
- Important Variable (Continuous Processes, Batch Processes, Temperature, Pressure, pH, Velocity & Process Chemistry)
- Test Methods (Real-Time Versus Accelerated Test, Metals & Alloys, Plastics & Elastomers) Designing a Corrosion Testing Program (Existing Processes & New Processes)
Material Selection Criteria
- Product Contamination
- Reliability
Materials Selection Procedure
- Low-Temperature Toughness
- High- Temperature Degradation
- Grouping Process Regions
- Upset Conditions
- Corrosion